Plaster-wall-board construction



April 15, 1930. KNODE 1,754,429

, YPLASTEIIR WALLBOARD CONSTRUCTION Filed Sept. 25, 1922 5 Sheets-Sheet l"- INVENTOR.

' I 0.1/- )(nooe W M g ATTORNEYS.

o. M. KNODE PLAS'IIER WALLBOARD CONSTRUCTION April 15, 1930.

s Sheets-Sheet 2 Filed Sept. 25. 1922 INVENTOR Cl M Kn 0 0 a ATTORNEYS.

April ,15, 1930. o. M. KNOD E PLASl'ER WALLBOARD CONSTRUCTION Filed Sept. 25. 1922 a Sheets-Sheet s P: INVENTOR I QM/(nooa ATTORNEYS.

Patented *Apr. 15, "19 30 jumrao srAT omvnn n. more, or wmivnrxja, ILLINOIS, assrenoa'ro 11mm sums mu couumr, or cnrcaeo, rumors, a-conroaa'rron or rumors rnas'rnn-warnnoann cons'rnucrron Application filed September 25, 1922. Serial No; 590,858..

This invention relates to improvements in building materials and more particularly to plaster'wallboard construction.

I In the building trade a pulp, composition or plaster panel board that, when nailedto the hair crack in the filler is to be prevented.

studdingof the interior of a building, maybe covered with strips of wood at the .joints, painted or papered over without first covering with plaster is called wallboard While 0t er substitutes of lath and plaster that must first be covered with a coat of plaster a're called'plaster board. In wallboard having a plaster body, the surface covering is of better grade than plaster board and it is extremely important that the longitudinal edges of wallboard are well formed and of uniform thickness so that when the boards are placed edge to edge in forming the wall the surface will be uniform and flat, in other words the surfaces presented will substantially be in the same plane.

This effect is generally produced by cover ing or binding the longitudinal edges in plaster wallboard to prevent the plaster adjacent the edges becoming broken, crumbling or falling out during handling or transportation which will cause reduced thicknesses at un-' even points along the edges and, when applied to the wall, will cause hollows in the wall surfaces. Even with bound or covered edge plaster wallboard it is customary to cover the space between the ad'acent edges with a panel strip or fill'the crac with a putty likesubstance called crack filler to insure a smooth surface to paint orpaper over. It has been found thatit is advisable to leave a small space between ad'acent edges to allow-the crack filler to'bond to both boards if a slight It is an ob'ect of this invention to provide a plaster wall card without binding orcoverin the ed e that will maintain consistent thickness 0 the edge uniformlythroughout and at the same time provide a suflicient s ace between adjacent boards when secure "in place 'upon the wallfor the crack filler.'to

hbondieydcover the joint without the formation of cracks between the boards, it being understood that such a wallboard may be apj plied and plastered over in the manner of a plasterboard inthe sense as above defined, may be cut in smallerdimensions of customasrAraurorl-"ics ary plaster board and used as such, made originally in such dimensions, or the seconds orv imperfect boards cut down and used as plaster board. t

Among the-advantages of this invention are that this unbound or raw. edge plaster wallboard is more economical to manufacture than one, with the covered or bound edge, as this board is completed when it leaves the forming rolls and does not require any further treat-' ment, such as trimming, which not only requires the presence of an operator but causes wastage of paper and plaster, and the improved formation of the edge hereinafter described makes a better joint for crack filler While the preferred orm of means for constructing this improved plaster wallboard is illustrated on the accompanying sheets of drawing, yet minor detail changes may be made without departing from the 'scopeof this invention. I

, In the drawings,

Figure 1 illustrates in side elevation, a form of apparatus for constructing thisimproved than the rounded or s uare edged wallboard.

plaster wallboard, partly in section, showing the board forming end of the machine.

Figure 2 is a top plan view'of Figure 1, with parts removed.'

Figure 3 is a view in side elevation, partly in sections, of a portion of the machine next adjoining that shown in Figure ,1.

Figures 4 and 5 are sectional views taken on the lines 4-4 and 55 on Figures 1 and 3 respectively.

Figure 6 is a view corresponding to Flgure.

- .4- showinga modification.

Figure 7 is a view in vertical longitudinal section of the part of themodified machine adjacent the section illustrated in Figure 6. r

Figures 8 and 9 areviews in perspective of forms of plaster wallboard constructed in accordance with-this invention, illustrating the transverse edges in sections.

Figure 10 illustrates the adj acent boards manner in-which are secured to the studdmg I F' re 11 isa'view similar to Figure 4 of a l 'modi ed form of machine.

of a table-3 over which it passes to the forming rolls 4 and 5. As it passes over the table the lon 'tudinal ed s 6 each pass over an 'gular s aping mem rs 7 which tilt up the sheet for a short distance adjacent each ed e so that as it passes between the forming rolls, a section of the sheet there through will be of dish like conformation, see Fi ure 4. A pair of holding rolls 8 are prefera lyprovided to exert ressure on the main body of the sheet to ho d it flat upon the table as the edges travel up upon the angular shaping members 7 and if it is desired to make the bend in the where it tilts up from the body more edfigs de ite scoring wheels 9 may be employed to impart a reduction in the thickness of the paper at this point and will insure a uniform 7 width between the angular edges 6. As the bottom sheet advances plaster or like mate- "rial 10 in a plastic state is delivered upon the center of thesheet, preferably by a belt conveyor 11 which may be of the usual construction used in this art.

A top cover sheet 12 is applied over the plastic mass as it passes'through the forming rolls by passing it from a aper roll 13.over r formlng roll 5; he lower forming roll 4 ls-provided at each end with a tapered conical enlargement 14 corresponding in shape to the angular shaping members 7 on the table. To retain the mass of plastic material upon the bottom cover sheet 1 as it approaches the forming rolls and as it passes there through plates 15, preferably of glass or such material to which the plastic mass will not adhere readily, are arran ed on each side of the ar sha ing mem rs and extend along ends 0 the upper forming roll 5 to a point therebe 0nd.

The flat table 3 is preferably continued beyond the forming rolls 4 and 5. over which the formed board travels andit is also referable to provide a ar shaping mem rs 16 similar to the mem re 7 on the other side of the forming rollsand over which the formed beveled edges travel to support the edge in that shape until the plastic body has set more firmly. It'is also referable to extend the plates 15 on each si e 'of these latter members 16 thro tend above them to the top of the formed board. A means for mainta nin the of both cover sheets in contact wi the y of the formed board in the form of belts '17 ar is also preferable to ranged ll ilo-1 m o th yn w ughout their length which plates eittom sheet and ti a P am edges y the p- From the table 3- the formed board passes onto a conveyor, preferably a continuous belt 18, see Figure 3, which may, if desired, have ilar to the members7 on the table for supportinglthe edges of the board as it travels there wit v It is also preferable to provide an ironing device throu h which this conveyor advances the formed oard while the plaster body is setting to insure a uniform bond between both cover sheets and the plastic body to produce an even and uniform surface on each side of the board. The ironing device preferably comprises a plurality of rollers 20 ar-- ranged under the .conveyor belt and over 'a shaping member 19 oneach side thereof simwhich the belt travels and a; correspond ing number of rollers 21 mounted in a vertically movable frame 22 arranged over the lower rollers 20 with another belt 23 traveling.

over rollers mounted at the ends of the frame and passing under the frame rollers 21 and resting upon the upper surface of the board. This frame is Wei hted and its downward movement is limitefb set screws 24 mounted in the frame adapte to rest upon brackets 25 extending from the fixed support of the under rollers 20. h

After the board has assed through the ironing device it travels orward on the same or another similar conveyor, not shown, for a distance far enough for the lastic body to set sufiiciently for the board? to be cut in lengths, removed from the conveyor and ond theorming rollsi) as shown clearly in igure 7, and vertical elts 26 are mounted on the table extending beyond the forming rolls to take their place. These belts contact with the portion of the edge extending above the shaping members 16 and travel with the board so that'the ortion of plastic material at the edges of the oard-do not wipe over a stationary me ber. v

The width of the board is determined by the distance between the plates 15 and the thickness is determined by the distance between the forming rolls 4 and 5. The angle of bevel of the longitudinal edges is determined by the angles of the tapered conical enlar ments 14 onthe bottom forming roll 'ile it is referable to score the boting members 7 to form a trough to retain the plastic material such construction is not essential for any other-means may be employed to retain the plastic material on the sheet,-

as the bevels at, the edges are imparted at the time the top sheeti applied and the board formed by passing through the forming rolls 4 and 5.

Also while it is preferable to provide shaping members on the table and on the conveyor be nd the forming'rolls similar to those in rout of the rolls they are not essential if the mix of the plastic material .is such that it will have body enough to set sufficiently to maintain the bevel imparted to the edges in passing through the forming rolls.

- The object of beveling the longitudinal edges is two fold. The beveled edge permits the ready manufacture of a raw edge board is of sufiicient width and depth to be filled with crack filler 26v and make a smooth and continuous surface from one board to an- I other without hair cracks forming in the filler. A still further advantage of thisform of edge is that it allows the securing nails 27 to be either driven into the studding 28 a through the full thickness of the board or through the beveled portion and in the latter case, the nail heads will be completely covered by the crack filler.

While it is preferable to form the board with the edge-of one cover sheet beveled and extended to engage the other flat sheet, as shown in Figure 8, the engagement of the sheets is not essential to this invention. as

only a slight bevel is necessary to produce the desired results and the top sheet may be beveled and terminated at the edge a distance above the edge of the other flat sheet as shown in Figure 9.

Figure 11 illustrates a modification of the machine by-whichthe board is made with the bottom sheet extending flat throughout and the bevel or tilt given tothe top sheet by the top forming roll 5 having a conical enlargement 14 at its ends. In this form the bottom forming roll 4may be dispensed with and the table extended continuously under the upper roll 5 What I claim is:

The method of constructing raw edge plas ter wallboard having inclined, longitudinal edges, comprising the continuous advancing of a bottom sheet, depositing a mass of plastic material thereon, forming the plastic material evenly upon said sheet, applying the top sheet over said plastic body, forcing one only of the cover sheets at an angle along its longitudinal edges toward but not abutting the other sheet, the edges of the two sheets said exposed plastic material by a belt moving at substantially the same speed as the Wallboard in contact with said material said material has hardened and set.

- OLIVER M. KNODE.

until being separated a substantial distance to expose a portion of said plastic material along the edges of the wallboard, and supporting 

